System and method for applying a label for the automated production of e-vapor devices

ABSTRACT

A system for use in manufacturing vapor-generating articles may include a rotatable drum that is configured to hold a plurality of the vapor-generating articles. The system may also include a tagging drum that is configured to tag a respective label to a housing of each of the vapor-generating articles. The system may also include a pressing roller that is configured to press a leading edge of the label against the housing after the tagging. The system may further include a rolling drum that is configured to roll the label around the housing after the pressing.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority under 35 U.S.C. §119(e) to U.S.Provisional Application No. 62/094,743, filed Dec. 19, 2014, the entirecontents of which is incorporated herein by reference.

BACKGROUND

1. Field

This disclosure relates generally to systems and methods formanufacturing vapor-generating articles and, more particularly, tosystems and methods for manufacturing electronic vaping articles.

2. Description of the Related Art

Electronic vapor-generating articles may be manufactured via a number ofmanual operations. However, such operations are not only labor intensiveand time consuming but also more prone to inconsistency.

SUMMARY

Some example embodiments described herein are directed to automatedmanufacturing of electronic vapor-generating articles, such aselectronic vapor devices, regardless of their size and shape. Aspectsare directed to a labeler system for use in manufacturing electronicvapor devices. The labeler system is structured and arranged to tag(i.e., initially attach) a label to a rigid housing of an electronicvapor device, press a leading edge of the label against the housingafter the tagging, and subsequently roll the label around the housing.In this manner, the labeler system is useful as an automated system formanufacturing electronic vapor devices.

In accordance with aspects disclosed herein, there is a system for usein manufacturing vapor-generating articles. The system includes arotatable drum structured and arranged to hold at least onevapor-generating article (e.g., a plurality of the vapor-generatingarticles). The system also includes a tagging drum structured andarranged to tag a respective label to a housing of each of thevapor-generating articles. The system further includes a pressing rollerstructured and arranged to press a leading edge of the label against thehousing after the tagging. The system additionally includes a rollingdrum structured and arranged to roll the label around the housing afterthe pressing.

In accordance with additional aspects disclosed herein, there is amethod of applying labels to vapor-generating articles. The methodincludes arranging a vapor-generating article in one or more seats on anouter surface of a rotating drum. The method also includes tagging arespective label to a housing of each of the vapor-generating articles.The method additionally includes pressing a leading edge of the labelagainst the housing after the tagging. The method further includesrolling the label around the housing after the pressing.

In accordance with further aspects disclosed herein, there is a pressingroller used for applying labels to vapor-generating articles. Thepressing roller includes a roller body arranged adjacent to a rotatabledrum carrying a vapor-generating article to which a label is adhered atan intermediate location. The pressing roller also includes a pluralityof flutes in an outer face of the roller body. The roller body isconfigured to be driven relative to the rotating drum such that one ofthe plurality of flutes contacts a leading edge of the label and pressesthe leading edge of the label against the housing.

BRIEF DESCRIPTION OF THE DRAWINGS

Various aspects are further described in the detailed description whichfollows, in reference to the noted plurality of drawings by way ofnon-limiting examples of embodiments, in which like reference numeralsrepresent similar parts throughout the several views of the drawings.

FIGS. 1a, 1b, 1c, and 1d show electronic vapor devices in accordancewith various example embodiments;

FIG. 2a is a block diagram of a process for automated assembly ofelectronic vapor devices in accordance with an example embodiment;

FIGS. 2b-2d show aspects of systems and methods for the automatedmanufacture of electronic vapor devices using rotating drums inaccordance with an example embodiment;

FIG. 3 shows aspects of an automated system for applying a label to anelectronic vapor device in accordance with an example embodiment;

FIGS. 4 and 5 a show aspects of applying a label to an electronic vapordevice in accordance with an example embodiment;

FIG. 5b shows aspects of a drum in accordance with an exampleembodiment.

FIGS. 6a-6e show aspects of applying a label to an electronic vapordevice in accordance with an example embodiment;

FIGS. 7 and 8 show aspects of tucking an edge of a tagged label inaccordance with an example embodiment.

DETAILED DESCRIPTION

Various aspects will now be described with reference to specific formsselected for purposes of illustration. It will be appreciated that thespirit and scope of the apparatus, system, and methods disclosed hereinare not limited to the selected forms. Moreover, it is to be noted thatthe figures provided herein are not drawn to any particular proportionor scale, and that many variations can be made to the illustrated forms.Reference is now made to the figures, wherein like numerals are used todesignate like elements throughout.

Each of the following terms written in singular grammatical form: “a,”“an,” and “the,” as used herein, may also refer to, and encompass, aplurality of the stated entity or object, unless otherwise specificallydefined or stated herein, or, unless the context clearly dictatesotherwise. For example, the phrases “a device,” “an assembly,” “amechanism,” “a component,” and “an element,” as used herein, may alsorefer to, and encompass, a plurality of devices, a plurality ofassemblies, a plurality of mechanisms, a plurality of components, and aplurality of elements, respectively.

Each of the following terms: “includes,” “including,” “has,” “having,”“comprises,” and “comprising,” and, their linguistic or grammaticalvariants, derivatives, and/or conjugates, as used herein, means“including, but not limited to.”

Throughout the illustrative description, the examples, and the appendedclaims, a numerical value of a parameter, feature, object, or dimension,may be stated or described in terms of a numerical range format. It isto be fully understood that the stated numerical range format isprovided for illustrating implementation of the forms disclosed herein,and is not to be understood or construed as inflexibly limiting thescope of the forms disclosed herein.

Moreover, for stating or describing a numerical range, the phrase “in arange of between about a first numerical value and about a secondnumerical value,” is considered equivalent to, and means the same as,the phrase “in a range of from about a first numerical value to about asecond numerical value,” and, thus, the two equivalently meaning phrasesmay be used interchangeably.

It is to be understood that the various forms disclosed herein are notlimited in their application to the details of the order or sequence,and number, of steps or procedures, and sub-steps or sub-procedures, ofoperation or implementation of forms of the method or to the details oftype, composition, construction, arrangement, order and number of thesystem, system sub-units, devices, assemblies, sub-assemblies,mechanisms, structures, components, elements, and configurations, and,peripheral equipment, utilities, accessories, and materials of forms ofthe system, set forth in the following illustrative description,accompanying drawings, and examples, unless otherwise specificallystated herein. The apparatus, systems, and methods disclosed herein canbe practiced or implemented according to various other alternative formsand in various other alternative ways.

It is also to be understood that all technical and scientific words,terms, and/or phrases, used herein throughout the present disclosurehave either the identical or similar meaning as commonly understood byone of ordinary skill in the art, unless otherwise specifically definedor stated herein. Phraseology, terminology, and, notation, employedherein throughout the present disclosure are for the purpose ofdescription and should not be regarded as limiting.

Some example embodiments described herein are directed to a labelersystem for use in manufacturing electronic vaping articles, although thepresent disclosure is not limited thereto. Various embodiments aredescribed with reference to electronic vapor devices, but it should beunderstood that aspects described herein may be used with any type ofelectronic vaping article. The labeler system described herein mayinclude: a rotatable/rotating drum that is configured to carry one or aplurality of partially or completely assembled electronic vapingarticles; a tagging drum that is configured to tag (i.e., initiallyattach) a respective label to a housing of each of the electronic vapingarticles; a pressing roller that is configured to press a leading edgeof the label against the housing after the tagging; and a rolling drumthat is configured to roll the label around the housing after thetagging and the pressing. In this manner, example embodiments are usefulfor applying labels to electronic vapor devices during automatedmanufacturing operations.

Electronic Vapor Device Layout

Referring to FIGS. 1a and 1b , an electronic vapor device (article) 60is provided and comprises a replaceable cartridge (also called a firstsection or cartridge unit) 70 and a reusable fixture (also called asecond section or battery section) 72, which in an example embodimentare coupled together at a threaded connection 205 or by other suitablearrangements such as a snug-fit, detent, clamp, and/or clasp.

Generally, the second section 72 may include a puff sensor that isresponsive to air drawn into the second section 72 via an air inlet port45 that is adjacent to the free end or tip of the electronic vapordevice 60, a battery, and control circuitry. The disposable firstsection 70 includes a supply region and a heater that vaporizes apre-vapor formulation that is drawn from the supply region through awick. A pre-vapor formulation is a material or combination of materialsthat may be transformed into a vapor. For example, the pre-vaporformulation may be a liquid, solid, and/or gel formulation including,but not limited to, water, beads, solvents, active ingredients, ethanol,plant extracts, natural or artificial flavors, and/or vapor formers suchas glycerine and propylene glycol. In a non-limiting embodiment, thesupply region may be a liquid supply region that contains an e-liquid.

The first section 70 according to an example is a cartridge section andincludes an outer housing 6 that houses the liquid supply region,heater, and wick. Upon completing the threaded connection 205, thebattery of the second section 72 is connectable with the electricalheater of the first section 70 upon actuation of the puff sensor. Air isdrawn primarily into the first section 70 through one or more air inlets44 during drawing action upon the mouth end of the first section 70. Thedrawing action is communicated to a puff sensor in the second section 72which causes the battery-powered heater to vaporize some of the liquidfrom the liquid supply region. The vaporized liquid is entrained in theair that is drawn in through the one or more air inlets 44 and deliveredvia one or more ports at the mouth end of the first section 70. As shownin FIG. 1d , the one or more air inlets 44′ may be located at astructure associated with the threaded connection 205, including but notlimited to a connector ring between the first section 70 and the secondsection 72.

In an example embodiment, once the liquid of the cartridge is spent,only the first section 70 is replaced. An alternate arrangement shown inFIG. 1c includes an implementation in which the first section 70 and thesecond section 72 are integrally attached, such that the entireelectronic vapor device 60 is disposed once the liquid supply isdepleted. In such case the battery type and other features might beengineered for simplicity and cost-effectiveness while generallyembodying the same concepts as in an embodiment in which the secondsection is reused and/or recharged.

In an example embodiment, the electronic vapor device 60 may be about 80mm to about 110 mm long (e.g., about 80 mm to about 100 mm long) andabout 7 mm to about 10 mm or more in diameter. For example, in anembodiment, the electronic vapor device is about 84 mm long and has adiameter of about 7.8 mm. Implementations are not limited to thesedimensions, and aspects described herein may be adapted for use with anysize electronic vaping article.

At least one adhesive-backed label may be applied to the outer housing 6of the first section 70. The label may completely circumscribe theelectronic vapor device 60 and can be colored and/or textured. The labelcan include holes therein which are sized and positioned so as toprevent blocking of the air inlets 44.

The outer housing 6 may be formed of any suitable material orcombination of materials. Examples of suitable materials include metals,alloys, plastics, paper, fiberglass (including woven fiberglass) orcomposite materials containing one or more of those materials, orthermoplastics that are suitable for food or pharmaceuticalapplications, for example polypropylene, polyetheretherketone (PEEK),ceramic, and polyethylene. The material may be light and non-brittle. Inan example, the outer housing 6 is composed of metal, such as stainlesssteel, aluminum, or aluminum alloy.

Automated Manufacture Using Rotating Drums

FIGS. 2a-2d and 3 show aspects of systems and methods for the automatedmanufacture of vapor-generating articles (such as, by way of example,electronic vapor devices) using rotating drums in accordance herewith.Aspects of FIGS. 2a-2d and 3 are described with respect to automatedmanufacturing processes associated with the first section 70 (alsoreferred to herein as a cartridge unit 70) of an electronic vapor device60. The systems and methods described herein are not limited to use withthe first section 70, however, and instead may be used with automatedmanufacturing processes associated with a second section 72 (e.g., abattery section) and/or a combined article including a connected firstsection 70 and second section 72.

FIG. 2a is a block diagram of a process for automated assembly ofelectronic vapor devices in accordance with an example embodiment. Inembodiments, the process includes assembling and delivering open-ended,partially-assembled cartridge units 70 (step 10); establishing aprocession of the open-ended, partially-assembled cartridge units 70(step 11); adding liquid to the liquid supply region of the cartridgeunits 70 (step 12); inserting a respective downstream gasket into eachof the cartridge units 70 (step 13); inserting a respective mouth-endinsert into each of the cartridge units 70 (step 14); applying arespective label to the outer housing of each of the cartridge units 70(step 15); and connecting a respective battery section (i.e., secondsection 72) to each of the cartridge units 70 (step 16).

In aspects, the processes performed at steps 10-16 are automated, e.g.,using computer-controlled manufacturing machinery. In additionalaspects, the cartridge units 70 are handled and transported during andbetween steps 10-16 in an automated manner, e.g., using rotating drumsas described herein. In even further aspects, one or more inspectionprocesses is performed after each one of steps 10-16, e.g., to detectcartridge units 70 that are out of specification. The method is notlimited to the particular steps 10-16; instead, more or less stepsand/or different steps and/or a different order of steps may be used.

FIGS. 2b-2d depict drum-to-drum transfer systems and methods that may beused with aspects of automated assembly of electronic vapor devices inaccordance herewith. Aspects shown in FIGS. 2b-2d may be used in thehandling and transporting of cartridge units 70 during and between steps11-16 described with respect to FIG. 2a , for example. As shown in FIG.2b , a procession of a plurality of cartridge units 70 (shownindividually as solid circles) may be carried by a plurality of rotatingdrums 20-24 to work stations 26, 27 where manufacturing/assemblyprocesses are performed on the cartridge units 70. In aspects, the workstations 26, 27 may correspond to any of steps 11-16. In but oneexample, work station 26 may include machinery configured to insert arespective downstream gasket into each of the cartridge units 70, andwork station 27 may include machinery configured to insert a respectivemouth-end insert into each of the cartridge units 70. Although only twowork stations 26, 27 are shown for simplicity, it is understood thatrotating drums similar to drums 20-24 may be used to carry cartridgeunits 70 to other work stations during the automated manufacture ofelectronic vapor devices.

In example embodiments, each drum 20-24 may include a cylindrical bodywith a plurality of grooves (also called flutes) spaced apart on itsroll face. Each flute may be structured and arranged to hold and carry asection of an electronic vapor device, such as a cartridge unit 70. Asdescribed in greater detail with respect to FIGS. 2c and 2d , each flutemay include a resilient (e.g., yieldable) material that directlycontacts the cartridge unit 70 when the cartridge unit 70 is held in theflute and carried by the rotating drum.

Still referring to FIG. 2b , each drum 20-24 may include a vacuum systemthat selectively applies a vacuum force to the flutes to assist inholding the cartridge units 70 in the flutes during rotation of thedrum. For example, the system may be adapted such that during rotationof the drums 20-24, flutes that are located in shaded areas 30 areprovided with a vacuum force, while flutes that are located in unshadedareas 31 are not provided with the vacuum force. Specifically, aparticular flute on counterclockwise rotating drum 20 is provided withthe vacuum force when the flute is moving through the shaded area 30,and is not provided with the vacuum force when the flute is movingthrough the unshaded area 31. The vacuum force may be selectivelyapplied to each flute on each drum individually, such as via a vacuumport in each flute and a vacuum source internal to the drum thatselectively applies a vacuum force to the vacuum port in a particularflute based on the angular position of the particular flute along therotational path of the roll face of the drum.

Rails 32 may also be provided adjacent to one or more of the drums 20-24to assist in maintaining the cartridge units 70 in the flutes.Furthermore, cleaning air may be communicated to the port(s) of eachflute at angular positions such as that indicated by area 33. Thecleaning air may be selectively applied to each flute individually.

In aspects, when transferring a cartridge unit 70 from a donating fluteof a first drum to a receiving flute of a second drum, e.g., from drum20 to drum 21, a vacuum force is deactivated at the donating flute whenthe donating flute is at a location prior to the nip 35 between thefirst drum and the second drum. Also, a vacuum force is activated at thereceiving flute when the receiving flute is at a location prior to thenip 35 between the first drum and the second drum. This coordination ofthe timing of the respective vacuum forces applied at the donating fluteand the receiving flute is depicted by shaded areas 30 and unshadedareas 31 in FIG. 2b and facilitates moving the cartridge unit 70 out ofthe donating flute and into the receiving flute.

With continued reference to FIG. 2b , the system may include acontroller “C” that is operatively connected to one or more elements. Asdescribed herein, the controller “C” may be a computer-based controllerthat employs hardware and software to perform automated controlprocesses. For example, the controller “C” may be operatively connectedto one or more detectors 40 for the purpose of inspecting and/ortracking cartridge units 70 during the automated manufacturing. Thedetectors 40 may comprise cameras or other optical detecting mechanismsthat detect optical characteristics and/or information of the cartridgeunits 70 and transmit the detected optical characteristics and/orinformation to the controller ‘C’.

For inspection purposes, the controller “C” may determine whether acartridge unit 70 is out of specification, e.g., not properly assembled,damaged, etc., by comparing the detected optical characteristics topredefined optical criteria. Any cartridge unit 70 that is determined tobe out of specification based on the detecting may be ejected from oneof the rotating drums, e.g., by selectively disabling the vacuum of aflute carrying the out of specification cartridge unit and/or applying ajet of air to the flute, e.g., as indicated at location 41, to eject thecartridge unit 70 from the flute. It is envisioned that an inspectionstation may be located downstream of the ejection station 41, to confirmproper operation of the ejection station 41. The controller “C” may beprogrammed to track any empty flute position resulting from an ejection,and to track the empty flute position through the system (e.g., theentire system or to the next downstream workstation).

Alternatively or in addition, for tracking purposes, each cartridge unit70 may be encoded with information such as: date of manufacture, uniquetracking identification, authentication, lot number, facilityidentification, and model number. More specifically, the individualcartridge units 70 may be printed with indicia that provide suchinformation. The detectors 40 may include a device, such as a camera orbar code reader, which reads the encoded information on each of thecartridge units as the cartridge units are moved by the drums 20-24. Thecontroller “C” may be programmed to track the position of each cartridgeunit 70 in the system based on the encoded information detected by thedetectors 40.

As depicted in FIG. 2b , the controller “C” may also be operativelyconnected to the drums 20-24, for example, to control the rotationalspeed of each drum. The controller “C” may also be operatively connectedto the work stations 26, 27, for example, to control aspects of theautomated processes that are performed at the stations.

FIGS. 2c and 2d show aspects of the flutes and drums as describedherein. In embodiments, the flutes 50 that receive and carry thecartridge units 70 are embodied as grooves or channels at the outersurface (e.g., roll face) of the rotatable/rotating drums (e.g., drums20-24). As shown in FIG. 2c , in aspects herein, the longitudinal axisof the cartridge unit 70 is transverse to the direction of rotation ofthe drum when the cartridge unit 70 is seated in the flute 50. Eachflute 50 may include at least one port 52 that is in communication witha vacuum/pressure source of the drum. Depending on the angular locationof the flute 50 along the rotational path of the drum, thevacuum/pressure source of the drum may selectively apply a vacuum, anair jet, or no force at the port 52, e.g., as described with respect toareas 30, 31, and 33 of FIG. 2 b.

As shown in the magnified portion 53 of FIG. 2c , in embodiments thereis a clearance 54 between the roll surfaces of the respective drums(e.g., drums 20 and 21) at the nip 35 between the drums. For example,when the cartridge unit 70 has an outside diameter of about 7.8 mm, theclearance 54 may be about 0.5 mm to about 1 mm, although any suitabledimension of clearance may be used.

As shown in FIG. 2d , the surface of each flute 50 may be coated orcovered with a resilient (e.g., yieldable) material 55. An opening 56 inthe resilient material 55 aligns with the port 52 such that vacuum or anair jet may be applied to the flute via the port 52 and opening 56. Theresilient material 55 may be applied to surfaces of the drum outside ofthe flutes 50, for example, over the entire roll face of the drum. Inanother embodiment, the entire drum (e.g., drums 20-24) may beconstructed of the resilient material 55. In another embodiment, theresilient material 55 is provided over less than the entire flute 50;for example, a seat of resilient material may be provided in asub-section of a flute. Such a resilient material 55 may be used withany type of drum based on the system requirements, including but notlimited to a wrapping drum, MR drum, roll hand, etc.

In accordance with aspects herein, the resilient material 55 comprises amaterial that is softer (i.e., has a lower hardness) than the materialof the outer housing 6 of the cartridge unit 70. For example, in anembodiment, the outer housing 6 may be composed of a metal or metalalloy and the resilient material 55 may be composed of a plastic orrubber material. In an embodiment, the outer housing 6 is composed ofstainless steel or an aluminum alloy, and the resilient material 55 iscomposed of polyoxymethylene (POM, Delrin, etc.), although exampleembodiments are not limited to these materials and any suitablematerials may be used.

The resilient material 55 facilitates handling the cartridge units 70during the speeds that are involved with the rotating drums during theautomated manufacture of electronic vapor devices 60 as describedherein. In particular, the yieldable nature of the resilient material 55promotes a more complete seal of the cartridge unit 70 at the vacuumport in a flute, which enhances the vacuum retention force applied tothe cartridge unit 70 in the flute. Such arrangement assures retentionof articles on the flutes even at higher production speeds and/or withheavier, larger articles.

Labeler System

FIG. 3 shows aspects of a labeler system 200 for the automated applyingof labels to electronic vapor devices in accordance with an exampleembodiment. The system 200 may be, for example, part of a tippingmachine utilized in the manufacture of electronic vapor devices, such aselectronic vapor device 60. As described herein, a label or wrapper maybe applied to the exterior surface of the housing 6 of the first section(i.e., cartridge unit) 70 to provide a desired aesthetic appearanceand/or tactile feel to the electronic vapor device 60. The system 200may be part of an automated assembly path as disclosed in U.S.Application No. 61/979,326, filed Apr. 14, 2014, the entire contents ofwhich are expressly incorporated herein by reference. In addition, thesystem may include aspects of machinery described in U.S. ApplicationNo. 61/979,330, filed Apr. 14, 2014 and/or U.S. Pat. No. 5,024,242, theentire contents of both of which are expressly incorporated herein byreference.

In example embodiments, the system 200 may be used to perform step 15 asdescribed with respect to FIG. 2a . In such an implementation, thesystem 200 may include an accumulator 202 that receives and holds aplurality of cartridge units 70 after they have undergone processing ofsteps 12-14 as described with respect to FIG. 2a . The accumulator 202functions as a buffer between the machinery that performs step 14 andthat of step 15. The accumulator 202 may comprise, for example, azig-zag or S-shaped pathway through which the cartridge units 70 travelbetween an accumulator inlet and an accumulator outlet 203. Theaccumulator inlet may be vertically higher than the accumulator outlet203 such that the cartridge units 70 travel through the accumulator viagravity. The accumulator 202 may be sized to receive cartridge units atthe accumulator inlet at a faster rate than cartridge units are releasedat the accumulator outlet 203. In this manner, the accumulator 202provides a buffer that compensates for empty slots in the procession,e.g., cartridge units that were ejected from the procession based on theinspection step or missing in the procession as a result of inconsistentloading.

A sensor 204, such as a photo eye or similar, may be arranged at theaccumulator 202 to determine whether the amount of cartridge units 70 inthe accumulator 202 exceeds a threshold. The sensor 204 may beoperatively connected to a controller of the system 200. When the sensor204 communicates to the controller that the level of cartridge units 70in the accumulator 202 falls below the threshold, the controller maytemporarily stop the drums downstream of the accumulator 202, i.e., topause the labeling operation. This pausing permits cartridge units 70 toaccumulate in the accumulator 202 since the upstream equipment maycontinue to process and deliver cartridge units 70 to the accumulator202. The sensor 204 detects when a sufficient number of cartridge units70 has accumulated in the accumulator 202 (i.e., exceeds the threshold),at which time the controller, based on the signal from the sensor 204,automatically re-starts the drums of system 200 to resume the labelingoperation.

In example embodiments, a transfer drum 206 with flutes 50 around itsouter perimeter receives cartridge units 70 from the accumulator outlet203. The transfer drum 206 may be similar to the drums 20-24 describedwith respect to FIG. 2b . For example, each flute 50 of the transferdrum 206 is sized to receive a single cartridge unit 70. Each flute mayalso be provided with a resilient material 55 for contacting thecartridge unit 70. Each flute 50 may also have at least one aperture(such as port 52 and opening 56) that is configured to selectivelycommunicate a vacuum force to a cartridge unit seated in the flute 50,i.e., for keeping the cartridge unit 70 seated in the flute 50.

In example embodiments, the system is arranged such that rotation of thedrum 206 moves an empty flute 50 past and under the accumulator outlet203. Gravity pulls a cartridge unit 70 at the accumulator outlet 203into the empty flute 50. In addition to or alternatively to gravity, airpressure and/or a positive force applied by a wheel or belt may be usedto move the cartridge unit 70 at the accumulator outlet 203 into theempty flute 50. Vacuum may also be selectively applied to the flute 50to assist in pulling the cartridge unit 70 from the accumulator outlet203 into the empty flute 50. As the drum 206 continues to rotate, thetrailing wall of the flute 50 strips the cartridge unit 70 from theaccumulator outlet 203. Vacuum may be selectively applied to the flute50 to maintain the cartridge unit 70 in the flute 50 until rotation ofthe drum 206 brings the cartridge unit to the next rotating drum 100.

At location 210, the cartridge units 70 are transferred from thetransfer drum 206 to a drum 100, which rotates in a direction oppositethe rotation of the drum 206. Each cartridge unit 70 is held in arespective seat 115 on the drum 100 as described in greater detailherein with respect to FIGS. 4, 5 a, and 5 b. A tagging drum 215 issituated adjacent drum 100 and rotates in a clockwise direction. Inexample embodiments, the tagging drum 215 carries a plurality of labels220 and tags a respective label 220 to a respective cartridge unit 70 atlocation 225.

At location 230, each cartridge unit 70 with its associated label 220 istransferred from the drum 100 to a rolling drum 235, which rotates in aclockwise direction. Rolling drum 235 conveys each cartridge unit 70 andits associated label 220 into contact with belt 240. The belt 240 movesin a same direction as an adjacent portion of the surface of the rollingdrum 235 but at a slightly slower speed than the rotation of the rollingdrum 235, the speed difference between the belt 240 and the rolling drum235 causing the cartridge unit 70 to rotate in a direction that causeslabel 220 to wrap itself around the exterior surface of the cartridgeunit 70. After the wrapping operation, the labeled cartridge units 70are transferred from the rolling drum 235 to a downstream transfer drum245 for transfer to another station for further processing, such asconnecting the cartridge unit 70 to a second section 72 (e.g., asdescribed at step 16 of FIG. 2a ).

In example embodiments, an additional pressing roller 246 may beprovided adjacent to drum 100 at a location after the label is tagged tothe cartridge unit 70 and before the cartridge unit 70 is transferred tothe rolling drum 235. The pressing roller 246 may be structured andarranged to press an unsecured leading edge 305 (shown in FIG. 5a ) ofthe label 220 to the outer surface of the cartridge unit 70 prior to thecartridge unit 70 being passed to the rolling drum 235, as described ingreater detail herein with respect to FIGS. 7 and 8.

The transfer of the cartridge units 70 from one drum to another insystem 200 may be achieved using drum-to-drum transfer techniquesdescribed with respect to FIGS. 2b-d . The flutes of one or more of thedrums in the system 200 may be provided with a resilient material 55such as that described with respect to FIGS. 2c-d to facilitate safe andconsistent handling of the cartridge units 70 during high-speed rotationof the drums.

As described herein, the tagging drum 215 and the cutter 255 may be partof a tagging system that is structured and arranged to attach a label220 to a cartridge unit 70 held in seat 115. As described herein, therolling drum 235 and belt 240 may be part of a wrapping system that isstructured and arranged to wrap the label 220 around the cartridge unit70.

Still referring to FIG. 3, in aspects described herein the label 220 maybe an individual piece of paper or the like that is cut from acontinuous web 250. For example, a rotating cutter 255 or the like maycut the continuous web 250 into discrete labels 220 that are held to thesurface of tagging drum 215 by a vacuum. A heater 256, such as a hot airblower, heat plate, radiative element, etc., may be used to heat the web250 to increase the tackiness of the adhesive prior to tagging.

In example embodiments, a first side 260 of the continuous web 250 has apressure sensitive adhesive thereon, and a second side 265 of thecontinuous web 250 has no adhesive. In an embodiment, the pressuresensitive adhesive is pre-applied to the continuous web 250 and coveredwith a backing sheet 270. For example, the continuous web 250 may beprovided by a spool 275 with the adhesive and backing sheet 270 alreadythereon. The system 200 may be structured and arranged to unwind thecontinuous web 250 from the spool 275 and then peel the backing sheet270 from the continuous web 250 to expose the pre-applied adhesive priorto the continuous web 250 coming into contact with the tagging drum 215.The separated backing sheet 270 may be moved away from the continuousweb 250 using an air blower or the like. In embodiments, the spool 275is fixed to an E-shaft, and the RPM of the E-shaft may be controlled(e.g., selectively varied) to register (e.g., align) a printed logo on alabel with a position on the cartridge unit 70 via an eye.

The use of a pre-applied pressure sensitive adhesive (e.g., apeel-and-stick adhesive) on labels 220 provides an advantage overtipping machines that apply an adhesive or a solvent to the tippingpaper. In particular, the application of an adhesive or a solvent to thetipping paper requires a transient time at startup of the tippingmachine during which some tags are not useable. This leads to waste. Thepre-applied pressure sensitive adhesive used in aspects describedherein, however, does not require such a transient time during startup,and thus reduces waste. Implementations as described herein can pause inthe process of wrapping articles and restart with no loss of product;program stops (e.g., due to upstream equipment) will fully utilizelabeling.

FIGS. 4 and 5 a show aspects of applying a label 220 to a housing 6 of acartridge unit 70 in accordance herewith. As shown in FIGS. 4 and 5 a,drum 100 includes a cylindrical body with a plurality of flutes 105(e.g., pockets, groove, etc.) spaced apart across its roll face 110. Thedrum 100, including the roll face 110 and the interior surfaces of theflutes 105, may be composed of suitable material, including but notlimited to a metal or metal alloy such as steel. In embodiments, a seat115 is located in a pocket 117 of each flute 105, and each seat 115includes a seat groove 120 that is sized and shaped to hold a cartridgeunit 70.

As shown in FIGS. 4 and 5 a, a cartridge unit 70 is held in a seat 115in drum 100 when the tagging drum 215 brings the first side 260 (e.g.,the adhesive side) of the label 220 into contact with the exteriorsurface of the cartridge unit 70, e.g., at location 225 of FIG. 3. Inembodiments, the rotation of the tagging drum 215 and the drum 100 arecontrolled such that an intermediate location 300 of the label 220contacts the cartridge unit 70. More specifically, in an embodiment, theintermediate location 300 is between the leading edge 305 of the label220 and the trailing edge 310 of the label 220, and closer to theleading edge 305 than the trailing edge 310.

As shown in FIG. Sa, the contact location at the intermediate location300 is a length “d” away from the leading edge 305. In an embodiment,the length “d” is about 1-2 mm, although other lengths may be suitable.Making the contact point at an intermediate location 300 instead of theleading edge 305 yields improved tagging and rolling of the label 220 onthe relatively hard and unyielding outer surface of the cartridge unit70 (that is constructed, for example, of stainless steel or aluminumalloy) as compared to a tagging operation on a structure that has arelatively soft outer surface (that is constructed, for example, ofpaper, filter material, or the like) that yields at the locus ofapplication during the tagging process.

With continued reference to FIG. Sa, the seat 115 may include or beconnected to a post 400 having an internal channel 405. A first end ofthe channel 405 communicates with the hole 130 for providing vacuumforce at the seat. A second end of the channel 405, opposite the firstend, communicates with another channel 410 that is formed in the drum100 and which is in communication with a vacuum source 415 associatedwith the drum 100. In this manner, the vacuum source 415 associated withthe drum 100 may be used to selectively apply vacuum force at the seatvia the channel 405 and hole 130. In a non-limiting implementation, thepost 400 and channel 405 are embodied as a hollow cylindrical tube,although any suitable shape may be used.

In example embodiments, the post 400 is configured to be axiallymoveable inside the channel 410 as indicated by arrow 416. In aspects,the post 400 is sized relative to the channel 410 such that the lowerend of the post 400 remains the channel 410 through the entire range ofmotion of the seat 115. In this manner, vacuum may be maintained at theseat 115 when the seat 115 moves axially against the spring 125.

In aspects, the post 400 may be located inside the spring 125. Forexample, the spring 125 may have the shape of a helical spring, and thepost 400 may be centrally located within the spring and substantiallycoaxial with a longitudinal axis of the spring. More than one post 400and spring 125 may be used for each seat 155.

FIG. 5b shows a cross section of an implementation of drum 100 of FIG.3. As shown in FIG. 5b , the drum 100 includes a seat 115 with a seatgroove 120 that is sized to hold a cartridge unit 70. As describedherein, a swash plate 150 and a pusher 140 may be arranged toselectively push a cartridge unit 70 against the stop 135 during a labeltagging process. In embodiments, a screw 145 is threaded into the end ofthe pusher 140, with the screw 145 extending through a hole in the swashplate 150 without being threadedly engaged to the swash plate 150. Inaspects, a spring 900 surrounds the screw 145 and contacts the pusher140 and the swash plate 150. In operation, a cam follower or similarmechanism pushes a portion of the swash plate 150 inward, which appliesan axial force to the spring 900 and the pusher 140 that, in turn,exerts an axial force on a cartridge unit 70 in the seat 115. Theelements of the system may be structured and arranged such that theaxial force applied against the cartridge unit 70 in this manner issufficient to hold the cartridge unit 70 against the stop 135 andprevent the cartridge unit 70 from rotating in the seat 115 when thelabel is applied to the cartridge unit 70. The spring 900 advantageouslyprevents binding during this pushing operation so that the pusher 140will not damage the cartridge unit 70 during the pushing. Inembodiments, one or more circumferential springs 905 may be arrangedaround the pushers 140 to prevent the pushers 140 from pivoting out ofthe respective flutes of the drum.

With continued reference to FIG. 5b , the limit stop structure 133 maycomprise a shoulder bolt or the like. The extent of travel 137 of theseat 115 relative to the body of the drum 100 may be set to any desiredvalue (e.g., up to 1.5 mm or similar value) by raising or lowering thecutting drum assembly, which may be regarded as comprising the taggingdrum 215 and the cutter 255 (see FIG. 3).

As described herein, the seat 115 may include vacuum holes 130 that arein communication with a vacuum source in the body of the drum 100. Asshown in FIG. 5b , the vacuum holes 130 may be offset from (e.g., notcoincident) with the springs 125. The vacuum holes 130 may be incommunication with vacuum holes 410′ in the body of the drum 100 andthus used to selectively apply vacuum force at the seat groove 120 forretaining a cartridge unit 70 in the seat groove 120.

FIGS. 6a-6e show aspects of applying a label to an electronic vapordevice in accordance herewith. In embodiments, the drum 100 and taggingdrum 215 are sized and located relative to one another such that thetagging drum 215 causes the seat 115 to move along a radial direction ofthe drum 100 when the tagging drum 215 and/or a label 220 on the taggingdrum 215 comes into contact with a cartridge unit 70 carried in the seat115. As shown in FIG. 6a , the cartridge unit 70 is received in a seat115 on the drum 100 at nip location 210 and moves along a circular path600 toward the tagging drum 215 as the drum 100 rotates. In the locationshown in FIG. 6a , the cartridge unit 70 does not yet have a label 220tagged on its outer surface. As shown in FIG. 6b , during continuedrotation of the drum 100, the cartridge unit 70 comes into contact withthe label on the tagging drum 215 which moves (pushes) the cartridgeunit 70 and seat 115 radially inward relative to the drum 100 asdepicted by arrow 605. The spring 125 permits the seat 115 and thecartridge unit 70 thereon to be moved radially inward.

As shown in FIG. 6c , during continued rotation of the drum 100, thetagging drum 215 continues to move the cartridge unit 70 and seat 115radially inward until the cartridge unit 70 reaches a bottom dead centerposition. As shown in FIG. 6d , during continued rotation of the drum100, after passing the bottom dead center position, the spring 125 urgesthe seat 115 (and thus the cartridge unit 70) radially outward relativeto the drum 100 as depicted by arrow 610. As shown in FIG. 6e , duringcontinued rotation of the drum 100, the spring 125 continues to urge theseat 115 and the cartridge unit 70 radially outward until the cartridgeunit 70 is once again on circular path 600 and is no longer acted uponby the tagging drum 215. In the location shown in FIG. 6e , thecartridge unit 70 has a label 220 tagged (e.g., initially adhered) onits outer surface in the manner shown in FIG. Sa. From the positionshown in FIG. 6e , the drum 100 rotates the seat 115 and the cartridgeunit 70 past the pressing roller 246 and then to the nip location 230where the tagged cartridge unit 70 is transferred to the rolling drum235.

The sizing and spacing of the drum 100 and the tagging drum 215, and themovement of the seat 115 and cartridge unit 70, as described withrespect to FIGS. 6a-6e facilitates consistent and repeatable tagging(i.e., initially attaching) of labels 220 to the exterior surface of thecartridge units 70. Specifically, the movement of the seat 115 along theradial direction of the drum 100 causes the tagging drum 215 to maintainthe label 220 in contact with the cartridge unit 70 throughout anincluded angle of rotation a of the drum 100 without damaging therelatively hard housing of the cartridge unit 70. Maintaining the label220 in contact with the cartridge unit 70 through the included angle ofrotation in this manner increases the likelihood that the label 220 issuccessfully tagged to the cartridge unit 70 despite possible slightmisalignments of the label 220 on the tagging drum 215 relative to thecartridge unit 70 on the drum 100. The included angle α may be about 4degrees, although other angles may be used.

Rotary Label Tucker

FIGS. 7 and 8 show aspects of tucking a leading edge of analready-tagged label in accordance herewith. As described with respectto FIG. 5a , and as shown in FIG. 7, the leading edge 305 of the label220 is not attached to (devoid of contact with) the cartridge unit 70when the label 70 is first tagged to the cartridge unit 70 at thetagging drum 215. Specifically, the label 220 initially contacts andadheres to the cartridge unit 70 only at an intermediate location 300 ofthe label 220 between the label leading edge 305 and the label trailingedge 310. The housing of the cartridge unit 70 is a relatively rigidmaterial that permits only a very small area of contact of the label 220to the cartridge unit 70 when the label is initially attached (i.e.,tagged) to the cartridge unit 70, as opposed to structures that arerelatively soft and are slightly deformed to form a large flat area ofcontact for the label during the label tagging operation. Because therelatively rigid housing of the cartridge unit 70 permits only a smallcontact area for the label 220, it is relatively difficult to adhere theleading edge 305 of the label 220 to the cartridge unit 70 during thetagging, e.g., since even a slight misalignment of the label 220relative to the cartridge unit 70 could cause the leading edge 305 tofail to come into contact with the cartridge unit 70 during the tagging.Therefore, in example embodiments, the label 220 is tagged (initiallyadhered) to the cartridge unit 70 at the intermediate location 300between the leading edge 305 and the trailing edge 310 to increase thelikelihood that the label 220 is successfully tagged to the cartridgeunit 70.

Due to the label 220 being tagged to the cartridge unit 70 at theintermediate location 300, the leading edge 305 of the label 220 isunattached to the cartridge unit 70 while the cartridge unit 70 iscarried on the drum 100 toward the rolling drum 235. The unattachedleading edge 305 can lead to unlabeled or improperly labeled cartridgeunits 70. For example, at high machine speeds (e.g., high rotationalspeeds of drum 100), air acting on the underside of the unattachedleading edge 305 can peel (e.g., detach) the label 220 from thecartridge unit 70. This disadvantageously results in an unlabeledproduct that must be rejected. In another example, the distance “d”shown in FIG. 5a may exceed a desired amount which can result in theunattached leading edge 305 being folded back upon itself by the belt240 associated with the rolling drum 235. This disadvantageously resultsin an improperly labeled product that must be rejected. Accordingly,implementations described herein press the leading edge 305 of the label220 into contact with the housing of the cartridge unit 70 prior to thecartridge unit 70 being transferred from the drum 100 to the rollingdrum 235. This pressing adheres the leading edge 305 to the cartridgeunit 70 prior to the rolling operation at the rolling drum 235 andimproves the repeatability and yield of the labeling process.

Specifically, as shown in FIG. 7, a pressing roller 246 (also called arotary tucker) is structured and arranged to urge the leading edge 305of the label 220 into contact with the cartridge unit 70 while thecartridge unit 70 moves on the drum 100 between the location 225 (i.e.,where the label is tagged to the cartridge unit 70) and the location 230(i.e., where the tagged cartridge unit 70 is transferred to the rollingdrum 235). In embodiments, the pressing roller 246 comprises a rollerbody having an outer surface 720 with flutes 725 formed therein. Theflutes 725 are concave and have a shape that corresponds to the outerdiameter of the housing of the cartridge unit 70. In implementations,the pressing roller 246 rotates in a direction opposite the direction ofrotation of the drum 100. The rotational speed of the pressing roller246 and the distance between flutes 725 on the pressing roller areconfigured relative to the rotational speed of the drum 100 and thedistance between seats 115 on the drum 100 the such that a flute 725comes into contact with a label 220 on a cartridge unit 70 as rotationof the drum 100 moves the tagged cartridge unit 70 past the pressingroller 246. In this manner, the flute 725 of the pressing roller 246comes into contact with the leading edge 305 of the label 220 andpresses the leading edge 305 against the outer surface of the cartridgeunit 70, causing the adhesive on the underside of the label 220 toadhere the leading edge 305 to the outer surface of the cartridge unit70.

In example embodiments, the pressing roller 246 is constrained to rotatein a single direction, e.g., by running against a stop pin in a drivehub face. In the example shown in FIG. 8, the pressing roller 246 isattached to a rotational shaft 800 having a gear 805 fixedly attachedthereon. The gear 805 engages a gear 810 that is fixedly attached to adrive shaft that rotates the drum 100. In this manner, the pressingroller 246 is driven by the drum 100 and rotates in a direction oppositethat of the drum 100. In embodiments, the gears 805 and 810 areconfigured with a gear ratio to rotate the pressing roller 246 at aspeed relative to the drum 100 such that a respective flute 725 of thepressing roller 246 comes into contact with each tagged cartridge unit70 carried on the drum 100. For example, a gear ratio of 3:1 may beused, such that the pressing roller 246 rotates three times as fast asthe drum 100. Other gear ratios may be used. Alternatively, the pressingroller 246 may be driven independently of the drum 100, e.g., by adedicated motor, an E-shaft, etc.

In accordance with aspects herein, the pressing roller 246 may be springloaded relative to the shaft 800. In this manner, although the shaft 800is driven only in a single direction, the pressing roller 246 may rotatea small angle relative to the shaft 800 in a direction opposite therotation of the shaft 800. The spring loading of the pressing roller 246on the shaft 800 provides additional pressure on the leading edge 305 ofthe label 220 against the cartridge unit 70 when a flute 725 of thepressing roller 246 comes into contact with the label 220 on thecartridge unit 70. The additional pressure provided by the springloading helps ensure that the leading edge 305 is properly adhered tothe cartridge unit 70. The spring loading may be provided by anysuitable mechanism, such as a torsion spring connected between thepressing roller and the shaft 800.

In accordance with aspects herein, the pressing roller 246 may bespatially arranged relative to the drum 100 such that the pressingroller 246 depresses a seat 115 holding the cartridge unit 70 radiallyinward relative to the drum 100, e.g., in a manner similar to thedescribed with respect to FIGS. 6a-6e . Specifically, the root diameterof the flute 725 combined with the location of the pressing roller 246relative to the drum 100 can be configured to cause the flute 725 toremain in contact with the label 220 and cartridge unit 70 through anincluded angle of rotation of the drum 100. Maintaining the flute 725 incontact with the label 220 through the included angle of rotation inthis manner increases the likelihood that the leading edge 305 of label220 is successfully adhered to the cartridge unit 70 before the rollingprocess begins at the rolling drum 235. The included angle may be about4 degrees, although other angles may be used.

The pressing roller 246 may be constructed with any suitable materials.For example, the pressing roller 246 may be composed of a polymer suchas polyoxymethylene. In another example, the pressing roller 246comprises a metal body that is coated, at least at the flutes 725, witha polymer. Implementations are not limited to these materials and anysuitable materials may be used.

As described herein, the pressing roller 246 facilitates high speedlabeling on single and dual track drum based labelers. For example, thesystem described herein enables driving the drum 100 at speeds greaterthan 1000 RPM while ensuring that the labels 220 are properly tagged toand wrapped around the cartridge units 70.

While the labeler system 200 has been described with respect to labelingcartridge units 70, it is understood that the labeler system 200 mayalso be used to apply labels to battery sections 72.

The particulars shown herein are by way of example and for purposes ofillustrative discussion only and are presented in the cause of providingwhat is believed to be the most useful and readily understooddescription of the principles and conceptual aspects. In this regard, noattempt is made to show structural details in more detail than isnecessary for fundamental understanding, the description taken with thedrawings making apparent to those skilled in the art how the severalforms disclosed herein may be embodied in practice.

It is noted that the foregoing examples have been provided merely forthe purpose of explanation and are in no way to be construed aslimiting. While aspects have been described with reference to an exampleembodiment, it is understood that the words which have been used hereinare words of description and illustration, rather than words oflimitation. Changes may be made, within the purview of the appendedclaims, as presently stated and as amended, without departing from thescope and spirit of the present disclosure in its aspects. Althoughaspects have been described herein with reference to particular means,materials, and/or embodiments, the present disclosure is not intended tobe limited to the particulars disclosed herein; rather, it extends toall functionally equivalent structures, methods and uses, such as arewithin the scope of the appended claims.

1. A system for applying a label to a vapor-generating article, comprising: a rotatable drum configured to hold a vapor-generating article; a tagging drum configured to tag a label to a housing of the vapor-generating article; a pressing roller arranged downstream from the tagging drum, the pressing roller configured to press a leading edge of the label against the housing; and a rolling drum arranged downstream from the pressing roller, the rolling drum configured to roll the label around the housing.
 2. The system of claim 1, wherein the rotatable drum includes a drum body, a plurality of grooves in an outer face of the drum body, and a seat in each of the plurality of grooves, the seat including a seat groove that is configured to receive and hold the housing.
 3. The system of claim 2, wherein the vapor-generating article is an electronic vapor device, the seat is composed of a plastic, and the housing is composed of a metal or metal alloy.
 4. The system of claim 2, wherein the seat is moveable relative to the drum body along a radial direction of the drum body, the rotatable drum further including a resilient element configured to bias the seat outward along the radial direction.
 5. The system of claim 4, wherein the pressing roller is configured to push the seat along the radial direction of the drum body when the leading edge of the label is pressed against the housing.
 6. The system of claim 5, wherein the tagging drum is configured to push the seat along the radial direction of the drum body when the label is tagged to the housing.
 7. The system of claim 6, wherein the tagging drum is configured to engage the housing through an included angle of rotation of the rotatable drum.
 8. The system of claim 1, wherein the tagging drum is configured to adhere the label to the housing at an intermediate location of the label that is between the leading edge of the label and a trailing edge of the label.
 9. The system of claim 8, wherein the intermediate location is closer to the leading edge of the label than the trailing edge of the label.
 10. The system of claim 8, wherein the intermediate location is 1-2 mm from the leading edge of the label.
 11. The system of claim 8, wherein the tagging drum is configured to adhere the label such that the leading edge of the label does not contact the housing.
 12. The system of claim 1, wherein the pressing roller includes a roller body and a plurality of flutes in an outer face of the roller body.
 13. The system of claim 12, wherein the pressing roller is configured to be driven relative to the rotatable drum such that one of the plurality of flutes contacts the leading edge of the label that is tagged to the housing and presses the leading edge of the label against the housing.
 14. The system of claim 12, wherein the pressing roller is configured to rotate in a first direction, and the rotatable drum is configured to rotate in a second direction that is opposite to the first direction.
 15. The system of claim 12, wherein the pressing roller is configured to rotate at a first speed, and the rotatable drum is configured to rotate at a second speed that is different than the first speed.
 16. The system of claim 12, wherein the pressing roller is rotationally spring loaded.
 17. A method of applying a label to a vapor-generating article, comprising: arranging the vapor-generating article in a seat on an outer surface of a rotating drum; tagging a label to a housing of the vapor-generating article; pressing a leading edge of the label against the housing after the tagging; and rolling the label around the housing after the pressing.
 18. The method of claim 17, wherein the vapor-generating article is an electronic vapor device, the tagging is performed such that the leading edge of the label does not contact the housing, the pressing is performed with a pressing roller that includes a roller body and a plurality of flutes in an outer face of the roller body, and the pressing roller is driven relative to the rotating drum such that one of the plurality of flutes contacts the leading edge of the label that is tagged to the housing and presses the leading edge of the label against the housing.
 19. A pressing roller for applying a label to a vapor-generating article, comprising: a roller body arranged adjacent to a rotatable drum carrying the vapor-generating article to which the label is adhered at an intermediate location; and a plurality of flutes in an outer face of the roller body, the roller body configured to be driven relative to the rotatable drum such that one of the plurality of flutes contacts a leading edge of the label and presses the leading edge of the label against the housing.
 20. The pressing roller of claim 19, wherein the vapor-generating article is an electronic vapor device, the roller body is configured to rotate in a first direction, the rotatable drum is configured to rotate in a second direction that is opposite to the first direction, and the roller body is rotationally spring loaded. 